Flat-sized flexible envelope with insert

ABSTRACT

The flat oversize mail piece includes an envelope of expandable nature, a flexible insert within the pocket of the envelope and an item that may be rigid or non-rigid. In one embodiment, the insert is provided with a cutout that is asymmetrical to one side of the insert and envelope to matingly receive the item being shipped. In another embodiment, the insert is a thin plastic tray having a recess to receive the item being shipped and a plurality of cavities interconnected by thin webs that impart flexibility to the package.

This application is a Continuation-In-Part of pending application No.11/804,845, filed May 21, 2007.

This invention relates to a flat-sized flexible envelope with an insert.More particularly, this invention relates to a flat-sized flexibleenvelope having an insert for receiving an item to be mailed thatconforms to USPS requirements for flexibility and uniform thickness offlat-size pieces.

As is known, various types of envelopes have been constructed for use inmailing items, such as digital video disks (DVDs) and compact disks(CDs). In some cases, the envelopes have been provided with padding,such as described in U.S. Pat. No. 5,662,420, wherein a macerated paperlayer is sandwiched between two layers of paper.

In still other cases, as described in U.S. Pat. Nos. 5,544,473 and7,108,650, it has been known to provide envelopes in which a packingmaterial is inserted to receive an item for shipping.

Still other constructions have been known for use in shipping medicaltests specimens wherein a receptacle is provided to receive a testspecimen and the receptacle placed in an envelope, such as described inU.S. Pat. No. 5,620,097.

Recently promulgated United States Postal Service (USPS) regulations(see 39 CFR Part 111) provide standards for domestic mailing servicesthat set forth minimum flexibility and uniform thickness criteria forflat-sized pieces.

Accordingly, it is an object of the invention to provide a package thatsatisfies the criteria for flat-sized pieces of the USPS.

It is another object of the invention to provide an envelopeconstruction with a flexible insert for shipping items of rigid ornon-rigid nature.

It is another object of the invention to provide a packaged DVD thatqualifies for flat-sized piece postage in the United States.

It is another object of the invention to be able to mail an item, suchas a DVD or a CD, in a manner that qualifies as a flat-sized piecepostage in the United States.

Briefly, the invention provides a package that conforms to therequirements of a flat-sized piece for USPS requirements. The package ismade to hold the item to be mailed and a flexible insert that occupiesthe inside of the package in a manner that allows the package to flex.The item to be received within the envelope may be of rigid nature ornon-rigid nature.

In one embodiment, the insert has a cut-out of predetermined shape forreceiving an item to be shipped in the package so that the item isprevented from shifting within the package. In another embodiment, theinsert is in the form of a tray that has a recess for receiving the itemin a manner to prevent the item from shifting within the package.

In each embodiment, the flexible insert and the item being packaged canbe inserted into a pocket of a paper envelope of standard or anexpandable construction, as described in U.S. Pat. No. 6,227,444, and aflap of the envelope can be folded over to close the pocket. In eachembodiment, the flexible insert is of a height and width tosubstantially fill the pocket. Alternatively, the flexible insert andthe item may be inserted in a sleeve, plastic bag, shrink-wrapped inplastic, or wrapped with a web of paper or plastic or the like to formthe package for mailing purposes. Further, the envelope may be pre-linedwith padding to protect fragile items.

The insert may be fixed within an envelope by a glue or adhesive or theinsert may be slidably mounted within the envelope in an unsecuredcondition.

In the first embodiment, the insert is made of any suitable material,such a self-supporting plastic foam, corrugated paper board or the like.Typically, the cut-out in the insert is made asymmetrical and to oneside of the insert. For example, the insert is made of L-shape. Wherethe envelope has a dimension of at least 10 inches on one side, thecut-out in the insert may be located symmetrically within the insert andstill meet the criteria of the USPS for flat-sized pieces with a rigidinsert.

When the insert is in place, the package may be flexed or bent in thearea occupied by the flexible insert and particularly in a manner thatallows the package to conform to the above noted regulations of theUSPS.

In the second embodiment, the tray is made of a body of thin thicknessof plastic that is shaped, as by molding, with a cut-out in the form ofa recess that is sized to receive the item to be mailed. For example,the item may be a DVD holder, a CD holder, a pen, a cassette holder andthe like. In any event, the recess is typically disposed asymmetricallywithin the tray and the tray is provided with a pattern of wells orcavities to impart a flexibility to the tray as well as rigidity.

The cavities are disposed in the tray in spaced apart relation and areconnected to each adjacent cavity by a thin web of the tray body as wellas to the recess that holds the item to be mailed. The thinness of theinterconnecting web allows a cavity to pivot toward an adjacent cavityor the recess, if adjacent the recess, under a flexing or bending forceimposed on the package. Where the cavities are disposed in parallelrows, the insert can be flexed or bent along a line that passes within aweb in parallel between each two adjacent rows.

When the tray is in place, the package may be flexed or bent in the areaoccupied by the cavities and particularly in a manner that allows thepackage to conform to the above noted regulations of the USPS.

These and other objects and advantages of the invention will become moreapparent from the following detailed description taken in conjunctionwith the accompanying drawings wherein:

FIG. 1 illustrates a perspective view of an envelope construction inaccordance with the invention;

FIG. 2 illustrates a view taken on line 2-2 of FIG. 1;

FIG. 3 illustrates a view of a blank for making the envelope of FIG. 1with an insert secured in place in accordance with the invention;

FIG. 4 illustrates an exploded view of a package for mailing a DVD orlike cassette;

FIG. 5 illustrates a top view of a tray employed in the package of FIG.4;

FIG. 6 illustrates a left side view of the tray of FIG. 5;

FIG. 7 illustrates a front side view of the tray of FIG. 5;

FIG. 8 illustrates an exploded view of a package employing a modifiedtray and an expandable envelope in accordance with the invention;

FIG. 9 illustrates a top view of the tray of FIG. 8;

FIG. 10 illustrates a left-side view of the tray of FIG. 9;

FIG. 11 illustrates a front view of the tray of FIG. 9;

FIG. 12 illustrates a perspective view of a modified tray in accordancewith the invention;

FIG. 13 illustrates a top view of a modified tray similar to the tray ofFIG. 12;

FIG. 14 illustrates a side view of the tray of FIG. 13;

FIG. 15 illustrates a front view of the tray of FIG. 13 and

FIG. 16 illustrates a cross-sectional view taken on line 16-16 of FIG.13.

Referring to FIGS. 1 and 3, the envelope 10 is an expandable envelopeconstructed in a manner as described in U.S. Pat. No. 6,227,444 from aflat blank 11.

Referring to FIG. 3, the blank 11 includes a front panel 12 ofrectangular shape and a back panel 13 that is secured to the front panel12 along a horizontal fold line 14. In addition, the front panel 12 isprovided with a rectangular array of score lines 15; each spacedinwardly from the respective edge of the panel 12 to define a rectanglewithin the panel 12 and diagonally disposed score lines 16 that connectthe corners of the rectangle of score lines 15 with the corners of thepanel 12.

The back panel 13 has a score line 17 spaced parallel to the fold line14 to separate a trapezoidal section 18 located between the fold line 14and score line 17 from a rectangular section 19.

The blank 11 also includes a pair of side flaps 20 each of which isseparated from the front panel 12 by a fold line 21 and each of whichincludes a score line 22 at an intermediate point parallel to the frontpanel 12.

Each side flap 20 has a rounded end 23 at each end as well as a scoreline 24 that extends from the score line 22 on a side flap 20 to thecorner of the front panel 12.

Each flap 20 is to be folded over the fold line 21 into folded overrelation to the front panel 12. The back panel 13 is sized to besecured, as by an adhesive, to the folded over side flaps 20 to extendto and between the score lines 21 of the flaps 20.

The blank 11 also has a closure flap 25 that is secured to the frontpanel 12 along a horizontal fold line (as viewed) 26 and that includes ascore line 27 spaced from the fold line 26 to separate a trapezoidalsection 28 from a rectangular section 29.

Referring to FIGS. 1 and 3, the closure flap 25 includes a strip ofadhesive or glue 30, such as a gummed or latex adhesive, for closingonto the back panel 13 as well as a removable strip 31 that covers overthe adhesive 30 until the adhesive 30 is ready for use.

Referring to FIG. 3, each side flap 20 is provided with a line ofadhesive (not shown) on the underside (as viewed) of the section betweenthe score line 22 and the free edge of the flap 20 for securement to theunderside of the back panel 13.

In order to form the envelope 10 of FIG. 1, the blank 11 of FIG. 3 ismanipulated manually and/or mechanically in an automated manner in thefollowing manner.

First, the side flaps 20 are folded along the fold lines 21 over thefront panel 12. Next, the back panel 13 is folded about the fold line 14onto the exposed adhesive on the side flaps 20. In this respect, theback panel 13 is of a width to extend to and between the score lines 22of the side flaps 20, as indicated in FIG. 1. At this time, thetrapezoidal section 18 of the back panel 13 covers over the lower ends23 of the side flaps 20 in an overlapping manner and completely sealsthe two lower corners of the envelope 10. Also, the two upper corners ofthe back panel 13 lie over the rounded ends 23 of the side flaps 20 toleave the uppermost rounded ends 23 of the side flaps 20 exposed.

Once the back panel 13 is secured in place as shown in FIG. 1, a pocketis formed within the envelope 10.

Referring to FIG. 3, a flexible insert 32 is secured to the front panel12, for example by a suitable adhesive. As illustrated, the insert 32 isof L-shape and defines a cut-out located asymmetrically to one side ofthe insert 32 for receiving an item 33 (see FIG. 1) to be shipped in thecompleted envelope 10.

The insert 32 is made of any suitable material, such as a selfsupporting plastic foam, cardboard or the like. Preferably, alightweight plastic foam is used.

As indicated in FIG. 3, the insert 32 extends width-wise to and betweenthe vertical score lines 15 of the front panel 12 and extendsheight-wise to and between the horizontal score lines 15 of the frontpanel 12 in order to substantially fill the pocket of the envelope 10.

Referring to FIG. 2, the insert 32 has a thickness of from 1/16 inchesto 1¼ inches and preferably a thickness of ½ inch. The thickness of theinsert 32 may be up to ¾ of an inch.

Alternatively, the insert 32 need not be secured to either the frontpanel 13 or the back panel 13. In this case, the insert 32 may be slidinto the pocket of the envelope 10 after the envelope has beenfabricated. For example, the insert 32 may be inserted into the envelopeby a user when the item 33 is being inserted.

Further, the insert 32 may be dropped onto a die cut flat sheet and thenthe sheet closed around the insert 32 and rigid inserted item 33creating an envelope.

When the insert 32 is in place, the pocket of the envelope 10 isexpanded into the condition as indicated in FIG. 2. As viewed, theinsert 32 extends to and between the vertical score lines 15 of thefront panel 12 and to and between the score lines 22 of the side flaps20. Also, the edges of the front panel 12 beyond the vertical scorelines 15 bend downwardly, as viewed, and the sections of each side flap20 between the respective fold line 21 and score line 22 bend upwardly,as viewed, to define V-shaped side edges to the envelope 10. A similarV-shaped bottom edge to the envelope 10 is also formed. As a result, theinsert 32 being of a thickness equal to the largest width of theV-shaped side and bottom edges of the envelope 10 is restrained fromshifting sideways or vertically, and particularly, no more than 1 inchin an envelope 10 of a 9 inch×12 inch size with score lines 15 on thefront panel 12 being spaced ¼ inch from the edges of the front panel 12and the insert 32 being ½ inch in thickness.

Insertion of the insert 32 may be accomplished manually or automaticallythrough suitable mechanical equipment.

Referring to FIG. 1, the item 33 may be rigid, such as a DVD holder or aCD holder, or the item may be non-rigid, i.e. flexible. In either case,the item 33 is matingly disposed within the cut-out of the insert 32. Inthis respect, the item 33 has a shape corresponding to the shape of thecut-out and a thickness corresponding to the thickness of the insert 32.

The item 33 may be inserted into the cut-out of the insert 32 within thepocket of the envelope 10 manually or automatically. Further, the item33 and insert 32 may be inserted in the same operation by any suitablemeans. After the item 33 has been inserted into the cut-out of theinsert 32, the removable cover strip 31 is removed and the closure flap25 folded via the fold line 26 over the back panel 13 in order to closethe pocket and seal the item 33 therein.

Upon closing over of the closure flap 25, the trapezoidal section 28 ofthe closure flap 25 over lies the rounded ends 23 of the side flaps 20to seal the two upper corners of the envelope 10. At the same time, theremainder of the closure flap 25 is of a width equal to the width of theback panel 13 to form a neat closure herewith.

The envelope 10 may be of any suitable size. For example, for shipping aDVD holder, the envelope, when closed, has a width of 12-½″ and a heightof 10″. In addition, the insert 32 is of ½″ thickness and the DVD holder33 has a corresponding ½″ thickness, a width of 7.5″ and a height of5.25″.

The envelope 10 with the insert 32 therein conforms to the recentlypromulgated United States Postal Service (USPS) requirements for minimumflexibility criteria for flat-size pieces. As of Jul. 15, 2007, USPSregulation 301 (Physical Standards) found athttp://pe.usps.gov/text/dmm300/301.htm provides:

1.0 Physical Standards for Flats

1.1 General Definition of Flat Size Mail

Flat-size mail other than that in 3.0, Physical Standards for AutomationFlats, is:

-   -   a. More than 11-½ inches long, or more than 6-⅛ inches high, or        more than ¼ inch thick.    -   b. Not more than 15 inches long, or more than 12 inches high, or        more than ¾ inch thick, except for Periodicals mail under        707.26.0.    -   c. Rectangular with four square corners or with finished corners        that do not exceed a radius of 0.125 inch (⅛ inch).

1.3 Minimum Flexibility for Flat-Size Pieces provides a test as follows:

-   -   1. Place the piece with the length parallel to the edge of the        flat surface and extend piece half way off the surface;    -   2. Press down on the piece at a point 1 inch from the outer        edge, in the center of the piece's length, exerting steady        pressure;    -   3. The piece is not flexible if it cannot bend at least 1 inch        vertically without being damaged;    -   4. The piece is flexible if it can bend at least 1 inch        vertically without being damaged and it does not contain a rigid        insert.

If the piece is a flat 10 inches or longer and contains a rigid insert,the following tests are to be conducted:

-   -   1. Place the piece with the length perpendicular to the edge of        a flat surface and extend the piece 5 inches off the surface;    -   2. Press down on the piece at a point 1 inch from the outer        edge, in the center of the piece's length, exerting steady        pressure;    -   3. Turn the piece around and repeat steps 1 and 2. The piece is        flexible if both ends can bend at least 2 inches vertically        without being damaged.

The following test is for flats less than 10″ and that contains a rigidinsert:

-   -   1. Place the piece with the length perpendicular to the edge of        a flat surface and extend the piece one-half of its length off        the surface;    -   2. Press down on the piece at a point one inch from the outer        edge, in the center of the piece's width, exerting steady        pressure;    -   3. Turn the piece around and repeat steps 1 and 2; the piece is        flexible if both ends can bend at least 1 inch vertically        without being damaged.

The USPS requirements (1.4) for uniform thickness are:

Flat-size mailpieces must be uniformly thick so that any bumps,protrusions, or other irregularities do not cause more than ¼-inchvariance in thickness. When determining variance in thickness, excludethe outside edges of a mailpiece (1 inch from each edge) when thecontents do not extend into those edges. Also, exclude the selvage ofany polywrap covering (see 3.3) from this determination. Mailers mustsecure nonpaper contents to prevent shifting of more than 2 incheswithin the mailpiece if shifting would cause the piece to be nonuniformin thickness or would result in the contents bursting out of themailpiece.

The envelope 10 as shown in FIG. 1 that is stuffed with a DVD holder 33as described above and being of a size of 12½″ wide and 10″ high passesthe minimum flexibility criteria for flat-sized pieces of the USPS forflats 10 inches or longer that contain a rigid insert.

An envelope having dimensions of 9⅞ inches wide and 8 inches high with aCD holder 5⅞ inches wide×4⅞ inches high asymmetrically to one side ofthe cut-out in the insert 32 also passes the USPS minimum flexibilitycriteria for flats less than 10 inches long and that contain a rigidinsert.

The combination of envelope, flexible insert and packaged item may havedifferent relative sizes in order to pass the flexibility tests of theUSPS. For example, the envelope may have a maximum size of 12 incheshigh and 15 inches wide.

Further, the insert 32 may have one or more cutouts for receiving rigiditems other than rectangular items, such as DVD holders and CD holders.For example, for a large size envelope, the insert may have a cut-outthat is symmetrically placed. Further, such a cut-out may be of anysuitable shape such as rectangular, circular, or otherwise, to receive acircular item or otherwise. Further, the insert 32 may be provided witha slit in order to receive a slender item, such as a pencil.

As noted above, the envelope may be pre-lined with padding. In such anembodiment, the insert 32 may be fixed or not in place.

Referring to FIG. 4, a package 33 is formed of an insert 34 in the formof a rectangular tray and a wrapper or sleeve 35 that envelopes the tray34.

As illustrated, the tray 34 is made of a thin thickness of plastic thatis shaped, as by molding, with a cut-out in the form of a recess 36 thatis sized to receive an item 37 to be mailed. For example, in theillustrated embodiment, the item may be a DVD holder or the like. Therecess 36 is disposed within the tray 34 asymmetrically of the X and Yaxes of the tray 34 as viewed.

Referring to FIG. 5, the recess 36 is located in an upper left-handcorner of the tray 34. In addition, the recess 36 is of rectangularshape and is defined by a flat floor 38 and four flat side walls 39 thatextend upwardly from the floor 38. One or more projections 40 extendcentrally from each side wall 39 into the recess 36 in order to hold theDVD holder (not shown) between the floor 38 and the underside of eachprojection 40.

In addition, each side wall 39 has an enlarged section 41 at each endoutside the plane of the side wall 39 to form an enlarged corner 42 ofthe recess 36 for forming and protection.

The floor 38 of the recess 36 may be smooth and flat or may be formedwith a depressed design such as described below to impart rigidity andto receive the DVD holder (not shown) in a manner in which the DVDholder can be more easily removed.

The tray 34 is provided with a pattern of cavities or wells 43 to imparta thickness to the tray 34 as well as rigidity. These cavities 43 arespaced apart and are arranged in rows. As shown, there are two rows ofcavities 43 along the front of the tray 34 and three rows of cavities 43along the right-hand side of the tray 34 as viewed.

Each cavity 43 is of rectangular shape with a flat floor 46 and fourupstanding walls 47, each of which walls 47 is formed with verticalflutes or ribs 48, as viewed, in order to impart rigidity to the cavity45. As illustrated, the cavities may be of different sizes.

Referring to FIGS. 6 and 7, the underside of the flat floor 46 of eachcavity 43 is co-planar with the underside of the floor 38 of the recess36 and the walls 47 of each cavity 43 is of the same height as the walls39 of the recess 36.

A thin web 49 connects each cavity 43 with an adjacent cavity 43 and therecess 36 and each row of cavities with an adjacent row of cavities 43.The connecting webs 49 allow the tray 34 to flex between adjacent rowsof cavities 43, between the recess 36 and the adjacent row of cavities43 and between each pair of cavities 43 in a row. In this regard, thethin web 49 allows the bottoms of two adjacent cavities 43 to pivottoward each other.

A small flat flange 50 extends about the entire periphery of the tray 34

The tray 34 can be of any suitable size. For example, the tray 34 mayhave outside dimensions of 8.375 inches by 11.0 inches and a thicknessof 0.671 inches. The webs 49 may have a length of 0.30 inches betweenthe flutes or ribs 48 of adjacent cavities 43.

Referring to FIG. 4, once the item 37 (e.g. a DVD holder) has beenplaced in the recess 36, either manually or automatically by suitableequipment, the tray 34 may be slipped into the sleeve 35 with the sidehaving the front rows of cavities 43 being inserted first and the endsof the sleeve closed in conventional manner to form a package suitablefor mailing as a flat-sized piece in conformance with United StatesPostal Service (USPS) regulations (see 39 CFR Part 111).

When packaged, a flexing or bending force imposed on the side of thepackage occupied by the rows of cavities 43 causes the tray 34 to flexbetween the rows of cavities 43 as well as between the recess 36 and theadjacent row of cavities 43 and, particularly, in a manner to conformwith the above described United States Postal Service requirements forflat-sized packages.

Referring to FIG. 8, wherein like reference characters indicate likeparts as above, the package 51 may be made with a tray 34′ of a smallersize than the tray described above and an envelope 10 as described abovein the embodiment of FIG. 1.

The tray 34′ being of a smaller size, for example, having a recess 36for receiving a jewel case and with overall dimensions of 7 inches by8.875 inches, a lesser number of rows of cavities 43 is required. Inaddition, the overall thickness of the tray 34′ may be made smaller suchas with a height of 0.548 inches. Likewise, the size of the cavities 43may be different and the spacing between cavities 43 may be greater orless, e.g. with the webs 49 having a length of 0.25 inches between theflutes 48 of the cavities 43.

As illustrated, two rows of cavities 43 are disposed to each of twosides of the recess 36. In addition, the cavity 36 is formed with adepression 52 in the floor of the recess that has a pattern as shown inFIG. 9 with a circle 53 with four radiating channels 54.

Referring to FIG. 12 wherein like reference characters indicate likeparts as above, the tray 55 may be modified to have a recess 56 forshipping items other than CDs and DVDs. For example, the item might bean elongated pen (not shown) or any other suitably shaped structure.

In addition, the tray 55 is molded of a one-piece body to have aplurality of elongated cavities or wells 57 in a pattern wherein tworows of spaced apart cavities 57 extend from one side of the recess 56.Where the recess 56 is disposed angularly, as shown, to one side of thetray 55, one row of cavities has one more cavity than the other row tolie closer to the recess 56. In addition, a single cavity 57 is disposedon the opposite side of the recess 56 in line with the row having thelesser number of cavities. That is to say, the recess 56 is disposedangularly across the two rows of cavities 57 rather than being inparallel with a cavity 57.

Each cavity 57 has a rounded bottom 58 and an upstanding peripheral walldefining a pair of opposed side walls 60 and a pair of semi-circular endwalls 61 connecting the two side walls 60. In addition, a plurality offlutes 62, i.e. semi-circular grooves) extend across the bottom 58 ofeach cavity 57 and into each of the two opposed side walls 60.

The flutes 62 may be angularly disposed across each side wall 60 asshown in FIG. 12 or may be vertically disposed across side wall 60 asshown in FIG. 13.

The recess 56 has a flat bottom 63 coplanar with the bottom 58 of eachcavity 57 and a peripheral wall 64 upstanding from the bottom 63. Asillustrated, the peripheral wall 64 is of an ovate shape having a pairof parallel side walls 65 and a pair of semi-circular end walls 66connecting the side walls 65. In addition, one or more projections 67are provided on each of the side walls 65 for retaining an item withinthe recess 56.

In this embodiment, the recess 56 has a width of 0.701 inches betweenthe side walls 65 to receive a pen or the like. The tray 55 may haveoutside dimensions of 6.0 inches by 8.50 inches and an overall thicknessof 0.580 inches.

As illustrated, the recess 56 is asymmetrically disposed within the tray55, i.e. to one side of the tray 55. In addition, at least one cavity 57is disposed to one side of the recess 56 and two rows of cavities 57 areprovided on the opposite side of the recess 56.

As above, a thin web 68 extends between adjacent cavities 57 and betweenthe recess 56 and the adjacent cavities 57 to impart flexibility to thetray 55. In addition, a thin flange 69 extends about the periphery ofthe tray 52.

Referring to FIGS. 13 to 16, wherein like reference characters indicatelike parts as above, the recess 56 may have a rounded bottom 70 that iscoplanar with the bottoms of the cavities 57 and that is shaped toaccommodate the item, e.g. a pen, to be inserted into the recess 57.Likewise, each projection 67 is formed out of a side wall 65 of therecess 57 and is shaped to retain the item within the recess 53.

When the tray 55 is placed in an envelope, sleeve or wrapper, thesection of the tray 57 containing the multiple rows of cavities 57 isable to flex under a bending force in a manner to conform to the abovedescribed United States Postal Service requirements for flat-sizedpackages. In addition, the left-hand section of the tray with the singlecavity 57 is able to flex relative to the recess 56 along a lineparallel to the axis of the recess 56.

The trays in each of the above described embodiments is made of aplastic material that may be clear, translucent or opaque. Also, eachtray may be placed in an envelope of conventional structure, anexpandable envelope as described in U.S. Pat. No. 6,227,444 or a wrapperor sleeve.

The invention thus provides an insert or tray that is able to receiveand retain rigid or non-rigid items within an envelope or wrapper toform a package that can be mailed as a flat-sized piece as defined bythe USPS.

The envelope and insert satisfies the USPS requirement that a flat-sizedmail piece be uniformly thick so that any bumps, protrusions or otherirregularities do not cause more than ¼″ variance in thickness.

Excluding the outside edges of a mail piece, i.e., one inch from theedge, when determining variance in thickness, the insert secures theitem within the cutout of the insert 32 so as to prevent shifting ofmore than 2 inches within the envelope.

1. A flat-sized package comprising an item to be mailed disposed withinthe package; and a flexible insert disposed within the package toprevent said item from shifting within the package, said insert beingflexible within the area occupied by said insert under a bending forceimposed on at least one side of the package.
 2. A flat-sized package asset forth in claim 1 wherein said insert has a cut-out of predeterminedshape for receiving said item.
 3. A flat-sized package as set forth inclaim 2 wherein said insert is made of foam plastic.
 4. A flat-sizedpackage as set forth in claim 1 wherein said insert is a tray having arecess receiving said item.
 5. A flat-sized package as set forth inclaim 4 wherein said tray includes a pattern of cavities disposed inspaced apart relation and a plurality of thin webs interconnecting saidcavities to allow each said cavity to pivot toward an adjacent cavity.6. A flat-sized package as set forth in claim 1 further comprising an anenvelope receiving said item and said insert and wherein said packagehas a uniform thickness of not more than ¾ inch.
 7. A tray for a mailercomprising a thin plastic body; a recess disposed in asymmetric relationwithin said body for receiving an item to be mailed; a plurality ofcavities disposed in said body on at least two sides of said recess, atleast some of said cavities being disposed in spaced apart relation toeach other to define a thin web therebetween in said body.
 8. A tray asset forth in claim 7 wherein said recess is of rectangular shape havinga floor, a plurality of walls upstanding from said floor, and at leastone projection on at least one of said walls projection into said recessfor retaining an item therein.
 9. A tray as set forth in claim 8 whereineach said cavity has a floor coplanar with said floor of said recess, aplurality of upstanding walls, and a plurality of ribs on each said wallfor rigidifying said wall.
 10. A tray as set forth in claim 7 whereineach said cavity has a floor, a peripheral wall upstanding from saidfloor with a pair of parallel side walls therein and a plurality of ribsextending within and between said pair of parallel side walls and saidfloor for rigidifying said cavity.
 11. A tray as set forth in claim 7wherein said cavities are disposed in a pair of rows on each of twosides of said recess.
 12. In combination a tray comprising a thinplastic body; a recess disposed in asymmetric relation within said bodyfor receiving an item to be mailed; a plurality of cavities disposed insaid body on at least two sides of said recess, at least some of saidcavities being disposed in spaced apart relation to each other; and aplurality of thin webs in said body interconnecting said cavities; anitem in said recess of said tray; and an envelope receiving said trayand said item.
 13. The combination as set forth in claim 12 wherein saidenvelope has a pocket for receiving said tray and a closure flap forclosing over said pocket.
 14. The combination as set forth in claim 12where said envelope is prescored with an expandable pocket for receivingsaid tray.
 15. The combination as set forth in claim 11 wherein saidenvelope is a sleeve receiving said tray in slide fit relation.
 16. Thecombination as set forth in claim 11 wherein said envelope is a wrapperenveloping said tray and said item.
 17. In combination an envelopehaving a pocket; an item to be mailed in said pocket; and a flexibleinsert within said pocket having a cut-out of predetermined shapereceiving said item and being of a height and width to substantiallyfill the remainder of said pocket and to be shipped in said envelope.18. The combination as set forth in claim 17 wherein said insert issecured to said envelope.
 19. The combination as set forth in claim 17wherein said insert is made of self-supporting plastic foam.
 20. Thecombination as set forth in claim 17 wherein said insert is of L-shapeand said cut-out is disposed asymmetrically to one side of said insert.21. The combination as set forth in claim 17 wherein said envelope has aclosure flap for closing over said pocket.
 22. The combination as setforth in claim 17 wherein said envelope is a sleeve receiving saidinsert and said item in slide fit relation.
 23. The combination as setforth in claim 17 wherein said envelope is a wrapper enveloping saidinsert and said item.
 24. The combination as set forth in claim 17wherein said envelope has a dimension of at least ten inches on one sidethereof.
 25. The combination as set forth in claim 17 wherein saidinsert has a thickness of from 1/16 inches to 1¼ inches.
 26. Thecombination as set forth in claim 17 wherein, with an uppermost half ofsaid envelope supported on a horizontal plane, a lowermost half of saidenvelope is bendable relative to said horizontal plane about alongitudinal axis located at mid-height thereof to deflect a lowermostedge thereof for a vertical distance of at least one inch from saidhorizontal plane.
 27. The combination as set forth in claim 26 whereinsaid item is rigid.
 28. The combination as set forth in claim 27wherein, with an uppermost half of said envelope supported on ahorizontal plane, a lowermost half of said envelope is bendable relativeto said horizontal plane about a longitudinal axis located at mid-heightthereof to deflect a lowermost edge thereof for a vertical distance ofat least one inch from said horizontal plane.
 29. The combination as setforth in claim 28 wherein, with one side of said envelope supported onsaid horizontal plane and five inches of the opposite side of saidenvelope projecting in an unsupported manner, said opposite side of saidenvelope is bendable relative to said horizontal plane to deflect anedge thereof for a vertical distance of at least two inches from saidhorizontal plane.
 30. The combination as set forth in claim 29 wherein,with said opposite side of said envelope supported on said horizontalplane and five inches of said one side of said envelope projecting in anunsupported manner, said one side of said envelope is bendable relativeto said horizontal plane to deflect an edge thereof for a verticaldistance of at least two inches from said horizontal plane.